Apparatus for making castings



June 16, 1931. J, WILLIAMS A 1,810,509

APPARATUS FOR MAKING CASTINGS Filed Sept. 1l, 1929 3 Sheets-Sheet ll lf-l L J L l 56' l, 0 156 5,25r 15s 55 5I lllhI l UNIil 5@ 1 43 l 5e '-1 l E :I 11| 155 j;- I l 155 E 41 3 35 E 154 734 s 147 -4 ri 155 155 1g 24 2546 145 127 42 47 40 45 746' 15a l 3 y 150 120 Y l 152 5205/ ggf L 152 64 62 44 6967 'gz 32 A. 3 h- 6,5 m1- 7/ lIr 96' L l 90 @f 62 Z 87a l t l 14.13614 C@ 157 mmh 2 "uw" 13a /57 aucun,

11, 1929 3 Sheets-Sheet 2 J. H. WILLIAMS APPARATUS FOR MAKING CASTINGS Filed Sept.

June 16, 1931.

A.lime 16, r1931. J. H. WILLIAMS l 1,810,509 l APPARATUS FOR MAKING CASTINGS Filed Sept. l1, 1929 y l Jl/mento@ M Patented June 1931 UNiTanaairfare inthe ,mold either Wholly or partiallyemg, braces af part of the mold structure. Notable" examples of such, castings areV internal gearsV f SECURITY TRUsT COMPANY, or' DETROTTQMTCHIGAN; .a oonPonlAToNor ivirc'a'ienN;

APPARATUS" non Maxine CASTINGS# Application inea september 11, 1929. seraigira 391,783.

The invention relates'to the production of castings having either tubular or 'reentrant cross sections so that the casting When formed and also laps of va certain ktype -Which resemble internal gearsin'form and'vvhich are adapted 4for use inthe truing of ,external I 10` ratusby "thefuse of Which castingsr'of ,thel

y character referred to can'beproduced lv'vith a high ldegree of accuracy, n .Another object of the invention is the provision of an improved apparatus 'by the usefofwhich accurately formed castings'of the` characterllast-referred to canibe produced With'the metal of their inner surfaceshighly chilled and having'y the V'fine-grain structure characteristicof such chilled metal.; n

A'further object of the invention',v ancillary to those above noted, is the provision Vof an improved apparatus for removing solid metal cores or mold sections from tubular or're` Ventrant v section castings of the character re# Vferred to. y n 1 In the productionV of castings kbyl the use of f my improved apparatusthe casti'n'giis Yp'oured'- in Contact With an accuratelyfformed and smoothly finished metal core or other mold section having a form complementary to that e of theembracing surfaces of thefc'astifng to be produced. Then the casting andthe core or moldsection referred to are separated from Y the remainder of the moldand the Vjointbetween the casting and the core vor mold section is subjected to liquid pressure -until thel .liquid entersv betWeenand ylubricates theabutting surfaces of the casting and core or other mold section.y And, finally, theoore or mold section Ais forced from ,theembracing Walls ofthe'castmg. A

C As above stated, laps ofpthe 'character rej '/ferred to constitute a notable example of Y upper` `the apparatus.

F1g`.`4 isfa side elevationon a smaller scale l p 70,

castingsto which thel invention is applicable,

such laps `being in the general nature. of

axially elongated internal gears, and for purposes of explanation and illustration theipref erredapparatus forcarryingoutthe invention'ivill vbevdescribed in detail as applied to. 5 laps of this character, reference 'beinghadu to the' accompanying drawings 'showing .the

preferred (app aratus.

Int-he drawings:` y -H F-ig.1i`s a verticaly section through Vthe part of theapparatus for removingfthe.

'core from the-feasting.

Fig. 2 is 'a vertical section on'the line 242,

Figi 3 is anvenlarged jvertical ',vsec'ti'on;

Leo

through Va four-Way valve forming `part/of Y* of 4the lentire apparatus. y o,

Fig. 5 is a plan View of theapparatus shown in Fig.` 4; f

Fig. 6 is anenlargedvertical section ofthel A lap castingand the'fcore as theycome from" the mold. ,f y'

' Figi?" is a plan view innige- Figs. 8 and 9 shovvthe core and lap, respec- Qf disipar-ts ningn-.ed

tively, after they,^ have been,oseparate'd.Vv

Fig. 10 'is a verticalfsection on a reduced scaleof the entire mold kused inQcastingtheVv In; order that theuse of my improved ap- 'i paratus be 4vmore readily understood Iy 'Will first verybriefly describethe constructiv'on and use of the mold in which the cast# ing is formed, as shown in Fig-.10. The lapr is Y to,V be formed With' internal teeth .complementary to thosebf the spur -gears to be lapped thereby-and consequently.. the metall core oftheA mold-.must be formed With'ex-f ternal teethA siniilar'to thoseof such gearsg,

In Fig l0 the reference: character l*ind'iz.

cates the base portion of a Vmold which is formed offdry sand.'v Resting thereon in central position is a spindle gate'coreQ valso of y dry Vsand v'vithv sixteen spindles 3 formedthereon and equallyspaced around the core 2. Inthis core 2 at the base ofthe spindles i3 is anannular space 4, Which serves to transfer molten metal from the feeder passage 5 and pouring gates G to the spindles 3 from there into the `casting cavity 22 of the mold.

rlhe main body portion of the mold is divided on a horizontal plane into an upper section 7 and a lower section 3, both formed of dry sand. The Vlower body portion 3 has a recess 15 into which the core 2 is fitted. rIhe spindle core 2 has a recess 9 in its upper face in which is inserted an iron chill 10.

Complementary to core 2'and resting in a recess 11 in the upper body portion 7 of the mold is another dry sand core 12, which has formed therein four openings 14 equally spaced around the core 12. In the upper and lower sides of the body portions 7 and 8 respectively, are recesses 16 which allow communication between the spindles 3 and the cavity of the mold, and also betweensaid cavity and the riser openings 14. The core 12 has a recess 17 for the reception of a second,V

iron chill 18. f l

In .the center of the mold and resting on lower chill 10 isa steel core 19. Extending through this core 19, and also lower core 2, chills 10 and 18, and upper core 12 is a central bore which is adapted to receive the central rod 20. Resting on the top of the core 12 and rod 20 is a weight 21. Surrounding the mold is a'flask 22a. A'space 225 is provided between the walls of the mold and flask for the reception of green sand.

The mold is assembled and operated as follows: The base slab 1 is placed on a bottom of green sand, which is leveled olf for the reception of the base. Core 2 is fitted into the recess 15 of lower body portion 3 and is placed on base 1. Iron chill 10 is then placed in recess 9. Steel core 19 is then placed in posi- .tion,'and upper body portion .7 is then placed on lower body portion 8. Core 12 is then placed in recess 11 of mold section 7. If the steel core 19 does not match the mold in length, upper body portion 7 is rubbed on lower portion 3 until they do match. In practice portions 7 and S are purposely made longer than is required so as to insure a proper fit. The mold is then taken apart and the feeder passages 5 are cut. rlfhe mold is thenreassembled leaving out core 19, core 12 and chills 10 and 18,'and pouring gates 6 are then pasted thereon so that they will register with the feeder passages. 'Ihe entire mold is then covered with paper. The flask 22a is placed around the mold and space 226 is packed with green sand until it is level with the top of the mold. The steel core 19 is then preferably coated, while at a temperature of about 100o F., with a solution of bone bla-cl:A in water. The chill 10, the steel core 19, chill 18, core 12, rod 20 and weight 21 are all placed in position. Molten metal 1's then poured into gates 6 until it appears in risers 14. The casting is allowed to cool until it is thoroughly congealed and then the mold is broken away and the steel core 19 with the cast-ing is removed and set upon its end to cool.

l/Vith the above described mold and procedure the casting produced, particularly the metal at the inner surfaces of the lap, is strongly chilled and is correspondingly hard and dense. However, by a modified method it is possible to produce soft iron laps or other castings. In this latter case the chills 10 and 13 are omitted and the metal core 19 is preliminarily heated in a suitable manner to control its chilling effect while, at the same time, the advantages of accurate form of the core are retained.

lVhether the casting produced as above described be chilled or soft, as it cools it contracts and more or less strongly grips the core 19 with the result' that the removal of such a solid core from the casting without damaging the core or casting has heretofore been a practically insurmountable obstacle. But by use-offmy improvedapparatus I am enabled to accomplish vsuch removah The means for separating the lap from the steel core 19 is shown in Figs. 1 to 9, inclusive. Y

The steel'core 19 with a cast iron lap 23, as it comes from the mold is shown in Figs. 6 and 7. The registering teeth of the core and lap are indicated at 24 and 25, respectively. Figs. 8 and'9 show the core and lap after they have been separated by the method and apparatus hereinafter described.

YReferring to'Figs. 1, 2 and 4 in detail: The apparatus has an upper rigid clamping ring 30. Clalnped to this ring by means of bolts 31 and nuts 32 is an adapter plate 33. Different size adapters can be used for different size laps. Anopening34 is provided centrally of the adapter so that the core 19 may be ejected from the lap 23. A boss 35 projects upwardly from the adapter plate and is arranged around the periphery of the opening 34. This boss is provided with screw threads for the reception of a casing 36. A

cover 37 is attachedrto the casing means of screw threads or the like. Two openings 33 are provided in the .ring 30 for the reception of tie rods 82 for a purpose to be hereinafter described;A

Arranged below and spaced from the clamping ring 30 and adapter 33, is a movable clamping plate 40. In the operation of the device the lap 23 is rigidly held lbetween these clamping elements 33 and 40. Packing ringsf41 and 42 are provided at the upper and lower ends of the lap 23 so as to prevent oil from'escaping. A central bore 43 is provided in the plate 40 for the recep-` tion of a ram rod 44. It will be noted that on core 19 and lap 23 respectively, extensions 45 and 46`have been provided. Extension 45 extends into the upper part of bore 43 and extension 46 rests on the clamping plate 41. This arrangement of the two extensions just described withrelation tothe plate 40 provides an vannular space 47 between theplate 40 and-the coreand' lap', for a purpose to be hereinafter described. The plate 40 is pro# vided with a passageway 48 (Fig. 2) which l leads to the annular space 47 for the pasy sagefof liquid under pressure.

A piston 53 is rigidly attached to this mov* able clamping plate by means of a split m fring fitting into a groove'51 in the piston.

This ring is securedto the plate 40 by means ofv screws 54. This piston is litted into arecess 55 in the clamping plate 40.

The piston has an integral head 56 dis- 15,posed inthe cylinder 61. rThis head has an Y annular iiange57, to which the packing rings 58 and 59are secured by means of bolts 60, thereby forming a liquid tight i'it in the cyl-v inder 61'.

means' of `plates. 62 andv .63 secured to the The cylinder 61 is closed at both ends by cylinder by means of tie bolts 64 and nuts These bolts extend through the body of cylinder andI securethe plates to the ends y ggthereot. The plate 62has an opening 66 in itsv center for the purpose oli receiving the upper` end of the piston 58. A liquid tight fit isy provided between thev piston 53 and plate 62 by a packing means 67- which is :im cured in the recess 68 01"' the plate by means ot vscrews 69, acting on a clamping ring 69a.`

An extension 7 5 is integralwith the piston head 56, and reciprocates in an opening 701in the lower cylinder plate 68, and thereby 35 forms a. guiding means for the piston.. Suit-v able packing rings 71 are vfitted in a recess72L in the plate 63 and are held in place-by means of a clamping plate 720; and screws 73. f

A. bore 76 extends centrally of piston 53 .uli-and piston extension for the reception of the ram rod 44., The lower end of extension, 75 has a recess 77 cut therein. This recess.k together with. packing 78 an deo-ver 79 form a stufling box Jfor the rain rod f i 45VT It willbe noted from anexainination of Fig. 1 'that the cylinder 61 has two solid inte- `gral extensions 80 arranged opposite each otheil and these extensions have openings 81 for the reception of tie rods 82, and also open- 50,ing's 83 `for the .reception of ybolts 64. The

i'einainingtie bolts 64' engagek the cylinder throughintegral flanges 84, seen in Fig. 2'.

The lower kend of ram rod'44 terminatesL Y inapiston 85. j This piston has an in egral 55..,li'ange 86 to which. packing rings 87 are secured by means of plate 87a and* screws 88. Enclosing the piston is a cylinder89 having integral extensions -90 inwhichfthe openings f91' lare provided forthe reception of the tie '6H-rods 82. Y

frheiewer ma '0l nthe @yiinder seis Closed by'mea'ns of ltheplate 92 and stud bolts 98. Theupper end isclosed by meansof a plate 94 and stud bolts 95. Theiplate 94 has a cenltral opening96 for the passageof the ram inder 61.

' rod 44.,"A suitable packing means 97 lis provided-in the opening 96 for theram rod, so

as to form a fluid tight connection.

The reference character100 denotes a pipe tion controls the flow of oil to the movable clamping plate.` Y l i The clamping cylinder 6,1 has oil ports 104 and 105 arrangedat its `upper and lower ends .respect`vely,so as to allow oil under pressure to enter the said cylinder on either side otpiston head 56 to -control the movement of the saine. i Oil also exhausts 4through ,theseports,10.4jand105.- "When one of the ports is acting as a means for introducing Connected i Vto move.'A A valve 103 of ordinary construcv oil under pressure the opposite port is acting Y as anV exhaust. This movement is controlled by means ofA the tour-way control valve 106, 1 l u wnich is shown .in detail -in Fig. 8. lne valve casing 107 of this valve 106 has our openings equally spaced around the saine.

The'opening 108 is connectedto the pressure line-100, and opening 109 is connected to the exhaustline 110 which leads toL a suitable oil supply reservoir (not shown). Openings 111 and 112'have connections which lead to the oil ports`104 and 105,respectively, of they cyl` The central valve member 113 is `adapted to'rotate in the casing 107, andhas two ports 114 cut in the bodythereofl at opposite sides so as;to establish,connectionsbetween the cylinder andthe two lines, that is the supply line 100 and the exhaust line 110. These connections .areeiiected inthe followllO ing manner: l/Vhen one end of the cylinder' 61 is incominunication withrthe supply lineby means of onefofthe valve ports 114, the other end ofthe cylinder will'bef in communicationH with the exhaust line 110,v through the other vvalve port 114.

site ends thereof. -These ports areconnected to supply line 100 and exhaust 110 by means of l*a secondfourway `valve 117 ',This fourn way Yvalvekll-.is identical, in yconstruction Gylinder89y has ports 115 and -116 at oppol and operation, with Jvvalve 106 described gY i above; `The movement of piston85 is con-' trolled by the operation of the valve 117finv l the saine manner that pistonhead y56 Vis controlled by yvalve'106.

The upper end of rainfrod see Fig. 1, hasfalreduced extension 120 which projects into bore 43ofclainping plate40.. In thisy extension120is a right-angle passageway- 121, which acts as a means for equalizing the oil pressure in a manner to be hereinafter' described.

Referring particularly lto Fig. 4, it will be seen that the apparatus is mounted on a base 125 which has a flange 126 provided around its outer edge so as to catch any oil which may leak out of the connections.

1n the movable clamping plate 40 an annulartrough 127 is provided to catch the oil which may escape when the lap 28 and core 19 are removed. Trough 127 is connected with a return oil pipe 128 which leads to the supply reservoir. Base 125 is connected by means of conduit 129 to this return pipe 128. See Fig. 4. A ed to be mounted on some suitable support (not shown) such as a floor of the building, or the like.

As can be vseen from ari-'examination of Fig. 4, tie rods 82 project upwardly from the base 125 on opposite sides thereof. The rigid parts of the apparatus are connected together by means of these Uie rods 82. 1t will be rnoted that the tie rod 82 has an enlarged section 181, the purpose of which is to keep the cylinders 61 and 89 spaced apart. Sleeves 180, 182, 188, 184 and 185 surround the rods 82 and also serve to keep the several parts of the apparatus separated as can be seen from an examination of `f`igs. 1 and 4. Nuts 186, 187 and 188 are attached to the tie rods so as to draw the several parts together on their spacing sleeves, thereby rigid- Wly securing the several parts to each other.

The movable clamping plate 40 has openings 150 through which the tie rods82 and spacing sleeves 182 extend. This 1s forthe purpose of guiding the movement of the plate 40.

1t will be seen from an examination of Figs. 1 and 2 that the steel core 19 has a bolt 145 with a beveled head 146 secured in its central opening 147 by means of a nut 148. The bolt 145 isplaced in the opening so as not to allow any oil to pass into casing 86 during one step in my process.

v1t will be noted that between the cylinder 61 and the ring 80 I have shown the several spa-cino' sleeves 188, 184 and 185 of diiferent lengths. These sleeves' are adapted to be removed or added at the will of the operator so as to adapt the machine to dierent length laps 28.

The operation of the apparatus is as follows: When the cast iron lap 28 and the embraced mold section (in this case the core 19) have cooled sufficiently after having been removed from the mold, the lap is machinedV or otherwise prepared for use. Then the bolt 145 is secured in the aperture 147 of the steel core 19 by means of the nut 14,8, and the steel core with the lap thereon is placed in position with the lap 19 registering with the opening 84 in theadapter plate 88. The

This base 125 is adaptpacking rings 41 and 42 having been placed in position, oil under pressure is admitted through four-way valve 106 to the port 105 of the cylinder 61 thereby moving the piston 58 upwardly. This piston 58 carries the lower clamping plate 40 with it. This plate 40 engages the projection 46 on the lap 28 and thereby firmly clamps the lap between it and the adapter plate 88. The projection 45 on the core 19 extends into the bore 48 of the plate 40. Cap 87 having been removed from theV casing 86, valve 108 is opened thereby allowing oil under pressure to enter the annular space 47 formed at the lower end of the lap and core, through the opening 48 in the plate 40. This oil under pressure is forced between the opposing surfaces of teeth 24 and 25. This latter action lubricates these surfaces and separates them to the extent of the thickness of the oil lilm forced between them, and the pressure of the oil on the lower end of the core 19 forces the lat-ter from the lap 28 and into the casing 86.

The above described operation is in most cases sufficient to extract the core from chilled iron laps. Should this operation fail to do the work, valve 117 is turned in such a manner as to allow oil under pressure to enter through port 116 to the cylinder 89. This operation will cause the piston 85 carrying the ram rod 44 to move upward. The continuation of this upward movement of the ram rod 44 causes it to strike the head 146 of the bolt 145 arranged in the central opening in the core and thereby mechanically ej ectV the core from the lap.

However, should this latter operation fail, the core and lap are then taken from between the two clamping plates, the bolt 145 is removed therefrom and the core and lap are then placed between the two clamping plates as before and thecap 87 is placed in position on casing 86. rltwill be noted that the upper end of ram rod 44 and also the projection 45 on the lower end of the steel core iit loosely inthe bore 48 of the movable clamping plate. lt will also be noted that a right-angle passageway 121 is located in the upper end of the ram rod44. Pressure is again admitted through valve 108 to the annulus 47. Oil under pressure will then find its Way into the upper easing 86 due to the loose tting of the projection 45 with the bore 48, the passageway 121 and the central opening 147 in the core; It will be seenthat oil under pressure is then being forced along the gear teeth 24 and 25 from both ends and this is continued until the oil has fully penetrated between and lubricatedy the abutting surfaces of the lap and core, and by expanding the lap or outer part, relieves the shrinkage pressure on the core, either in part or entirely, thereby causing separation of adjoining surfaces or relief of bearing between them. While the lap or outer part is thus under pressure valve 117 is igeiogsoe;

opened to allow oil under pressure to pass through opening 116, raise piston 85, and

' 37 is removed an d the core is then lifted oiit of the casing. Y e

When the abutting surfaces of the lap and core are lubricated in the manner described, thecore can be forced from the lap without undue pressure and consequently without injury to the said surfaces.k rllhe result is that by my'improvedmethod of castingV it is pos-` sible to produce a casting of annular or tubular ycross Vsection having its inner surfaces formed with a relatively high degree of accuracy. Also as pointed out, the casting can be made either chilled or soft. i

I have referred to the casting 28 as a cast iron lap and to the part 19 as a steel core, but it will be understood that this is for illustrative purposes only and that the casting may be either in the form of a lap, an internal gear or any other casting of'tubular or annular 1 shape or having reentrant walls, which it is desired to form with accurate surfaces or which itis desired to form of chilled metal. rFurthermore, it is obvious that the casting may be made of metals other than iron.

While I have described and illustrated the preferred procedure and preferred apparatus for the carrying out of my invention it will be understood that there can be wide Y `means for subjecting the joint between the moldsection and casting toliquid under pressure so as to separate them, said lastmen-` tioned means comprising` a passageway located in one of the said abutinents and connected to a supply of liquid under pressure.

i 2. In an apparatus of the class referred to, the combination of a pair of abutments spaced from each other and one of which -is movable toward and from the other, the said abutments beingl adapted to hold between them a casting and a metal mold section embraced by the walls of the said casting; means comprising a pasageway located in one of thek said abutments and connected to a source of liquid. under pressure for subject-ing the oint between the casting and the mold section to liquid under pressure and forcing liquid between the opposing surfaces of the casting and the mold section, and means adapted t0 forcibly eject ythe moldsection from the/embracingA walls of the casting. 'f

-. 85. In an apparatus of the classreferred'to, means for supporting a casting and a metal r mold section embraced; by the walls vof the said casting`said means comprising a stationary abutment'and a movable vabutment spaced therefrom; in coii'ibination with means for subjecting thef joint between vthe mold sectioni andcasting toliquid under pressure so asto separatethemaid last mentioned means comprising ar passageway located inthe mover ablez abutment;whichY isconnected toV a supply of liquidunder pressure, -V

` 4s.. Infan apparatus ofithe class referred to, the combinationv of a. stationary abutment and a movable abutmentspacedy therefrom, the said abutmentsbeing adapted to hold betweenv thema casting; fand a metal mold sectionembraced by the walls of the saidcasting means comprising a passageway: in the movable abutii'ient` connected to 1 a source of liquid pressure for subjecting the joint between the casting and the mold section to liquid under pressure and forcing liquid between the opposing surfaces of the casting and the mold sect-ion; and means adaptedto forcibly eject the moldV section from the embracing walls of the casting.

5. In an apparatus of the class referred to,

the combinationV of ay Vstationary abutment with a central recess therein; a movable" abutment spaced therefrom for clamping a casting withy ametal mold section embraced f,

by the wall of the casting therebetween in such a manner that the metal moldsection can be `forced through the aperture in the said stationary abutment; means for subjecting `the joint between the rcasting and the mold section to liquid under pressure and forcing liquid between the opposing surfaces of the moldvsection and casting; and hydraulically operated means for ejecting the mold section from the embracing walls ofthe castinO. Y f

td. In anapparatus of the class referred to,

-the combination of a stationary' abutment having aV central opening therein.; a casing r projecting from one side of said abutment and arranged around the said opening; a

, cover for said casing; a movable abutment spaced from the said stationary abutment, on

the side opposite to said casing, for clamping a casting' and a metal mold section embraced by the walls of the said casting against the Vsaid stationary abutment in such, a manner that the centery of the openingin the said stationary abutment is in alignment with vthe metal mold section of the casting; means for subjecting the joint between the metal Y mold section and casting to liquid under pressure,y at both ends thereof, and forcing liquid las between the opposingsurfaces of lthe mold Y section and casting ;V and a. hydraulically op-` erated means axially aligned with saidmold,

section and opening for forcing the mold section from the embracing Walls of the casting. 7. In an apparatus of the class referredto, astationary abutmentvwith a central opening; a hydraulically operated movable abutment spaced from said vstationary abutment for clamping a casting and a metal mold section embraced bythe Walls of the said casting against said stationary abutment in such 10 a manner that the center of the metal mold section Will be in axial alignment With the center of the opening in the said stationary abutment; means Jfor forcing liquid under pressure between the opposing surfaces of Y the mold section and casting; and hydraulically operated means in alignment With the metal mold section for ejecting the mold section from the Vembracing Walls of the casting through the opening in the said stationary abutment. l

In testimony whereof I aiiix my signature.

JAMES H. WILLIAMS.

Yes 

